Cap construction and the method of making same

ABSTRACT

The hat or cap disclosed is made of a sleeve of flexible material which is formed into four panels and two opposing panels are then folded inwardly. All of the panels are joined together at one end of the sleeve to form the cap.

United States Patent lnventors Robert Norman Speevak Montreal, Quebec;Joseph George Robert Paquin, Roxboro, Quebec, Canada Appl. No. 804,807

Filed Mar. 6, 1969 Patented Mar. 23, 1971 Assignee Johnson & JohnsonPriority Mar. 7, 1968 Canada 014,308

CAP CONSTRUCTION AND THE METHOD OF MAKING SAME 2 Claims, 6 Drawing Figs.

U.S. Cl 2/197 Int. Cl A42b 1/22 Field of Search 2/195, 196, 198, 200,174, 209.1, 197, 192, 201; 229/53; 19/161 {56] References Cited UNITEDSTATES PATENTS 1,996,367 4/1935 Davis 2/174 2,948,900 8/1960 Ebenstein2/209.1 1,659,425 2/1928 Blumenthal 2/174 1,785,637 12/1930 Lipper2/192XR 2,790,591 4/1957 Rosen.... 229/53 2,806,224 9/1957 Kursh 2/1742,862,251 12/1958 Kalwaites 19/161 FOREIGN PATENTS 458,758 8/1968Switzerland 2/198 795,001 9/1968 Canada 2/195 Primary Examiner-JordanFranklin Assistant Examiner-George H. Krizmanich AttorneysMichael Q.Tatlow, Harold L. Warner and Robert L. Minier ABSTRACT: The hat or capdisclosed is made of a sleeve of flexible material which is formed intofour panels and two opposing panels are then folded inwardly. All of thepanels are joined together at one end of the sleeve to form the cap.

PATENTED MR2 3 :97:

INVENTORS Robert Norman SPEEVAK .l. G. Robert PAQUIN H 1l. .-.-h

,4 7' TOPNEYS,

car cousraacriou sun was Maruon or Mxruivc SAME This invention relatesto hats.

More particularly, this invention relates to a novel cap constructed foruse as a head covering, finding application in various fields ofindustries.

Caps find use in many different fields of application where it isnecessary to cover the hair or the head of a person for various reasons.Such uses include, for example, caps for hospital personnel, serviceindustries such as the food industry, e. g. for waitresses, etc. in theprior art, there are several known types of cap constructions, such asthose illustrated in U.S. Pat. Nos. 2,869,135 and 2,990,552 and CanadianPat. No. 513,032. Such structures employ either several panels ofmaterial sewn together e.g. a central band of material contoured forcovering the major portion of the head attached to shaped side portionsand a rim; or when made of one-piece material, the caps involvecomplicated folds requiring several production operations, with theresult that the greater number of folds. the less APPLlCANTS DEVELOPMENTWith this invention, applicant has developed a cap having a greatlysimplified structure, and which permits a single size of the cap to fitmost people without the necessity of having to construct a large numberof different sizes. The cap structure permits the cap to readily conformto the contour of the head. it is also comfortable to wear and easy tomanufacture.

Thus, according to this invention the cap includes a sleeve of flexiblematerial made of a fabric having at least unidirectional elasticity. theelasticity being in the width direction, the cap having top and bottommarginal edges, with first and second opposed pairs of panels and thirdand fourth opposed infolded panels between the first and second panels,the top marginal edges of the infolded third and fourth panels beingjoined at least to one of the first and second panels at or near the topmarginal edge of the latter panel. and the first and second panels beingjoined at or near their top margins thereby to form a closed end to thesleeve of the flexible material.

According to a preferred embodiment of this invention, the infoldedthird and fourth panels, and the first and second panels are all joinedtogether along a single line at or near the top margins thereof. It hasbeen found that such a cap provides a more uniform structure andfacilitates manufacture thereof.

Preferably, all of the panels have a substantially equal length wherebythe equal length provides continuous uniform top and bottom borders. Allof the panels may have a substantially uniform width. However, as theshape of the human head is not circular, but rather to some extent anelongated oval, it may be desirable to make one pair of opposed panelse.g. the first and second panels a width greater than the width of thethird and fourth panels. According to a further preferred embodiment,the infolded third and fourth panels are actually divided into panelsections of equal width, each panel section extending between theopposed first and second panels a distance of up to about 50 percent ofthe width of the first and second panels. However, a panel may bedivided into panel sections of unequal width. In the preferredembodiment where the infolded third and fourth panels are each dividedinto equal panel sections, such an arrangement will form a substantiallyfour-ply thickness across the entire top margin, thereby providing addedreinforcement to the dome or top of the cap structure. If desired,however, the infolded panel sections could have a width less than about50 percent of the width of the first and second panels,i.e. from aboutto 45 percent, to achieve the type of elongated cross section notedpreviously.

The above preferred embodiment results in a cap structure having a pairof triangular gussets on the inside of the cap at the top thereofi.e.the dome portion, formed by each infolded third and fourth panel, andwhich is overlaid by the top portions of the first and second panels,with opposed inwardly extending triangularly shaped pockets in theexterior sides at the top, formed by the joint between the joined lirstand second panel sections and the infolded third and fourth panelsections. The pair of triangular gussets will be arranged such that theapex of each gusset faces the apex of the gusset of the other. Where theinfolded third and fourth panels are divided into equal panel sectionsand extend inwardly approximately 50 percent of the sides of the firstand second panels. the apexes of the gussets will be almost touchingeach other.

The material from which the cap of the present invention is made, asnoted above, is a flexible material having elasticity in at least onedirection, i.e. the width direction of the cap. whereby with the capstructure of the present invention. a single size cap may be provided tofit substantially all head sizes. The material of course. must benonirritating material. the most preferred material types have beenfound to be the fabric materials. The materials having the essentialcharacteristics according to this invention can be selected so that theyinclude additional characteristics and qualities required for any givenfield of use. Thus, for example, when the cap is to be used for hospitalworke.g. a surgeons capthe material selected .will have the property ofbeing sterilizable. Typical materials which may be used include nonwovenfabrics, such as those known under the trade marks Keybak; Masslinn; orother fabrics such as nylon, the product marketed under the trademarkLycra, cotton, etc. Also, mixtures of various fabrics may be employed.in -which at least the warp or weft threads forming the fabric possessesunidirectional elasticity. Other materials such as crepe paper may alsobe used.

If desired, the material from which the cap ofthe present in vention ismade can possess elasticity in both the width and length directions.

A most preferred fabric, where the cap is to be used for hospitalpurposes, has been found to be a nonwovcn textile material such as thatdisclosed in Canadian Pat. Nos. 653.278; 700,364 and bl2,l6l.

When employing a nonwoven fabric such as that known under the trade markKeybak. the weight of the fabric may range from to 1500 grains persquare yard. Preferably. the weight is somewhere around from 500 to l200grains per square yard. The Kcybak material is preferably either aviscose rayon or cotton material-alternately blends may be used. it mayalso be desirable to employ heat-scalable nonwoven fabrics. ln nonwovenfabrics, the elasticity is normally at right angles to the fiberdirection and therefore. the material will be used accordingly wherebyelasticity in the width direction of the cap is obtained. The degree ofelasticity required in the material from which the cap of the presentinvention is made will vary considerably.

Preferably. the elasticity is such that a single cap size is capable offitting substantially all head sizes. Using the preferred material. i.e.Keybak material with a grain weight of about 950 per square yard, a caphaving a diameter of 22 inches at its bottom margin has been found to beadaptable to most head sizes because of the cap construction having thedirectional elasticity feature.

Depending on the choice of material. the products of the presentinvention may either be of the disposable or nondisposable type. Thus.with the nonwoven fabrics. disposable products can be made at aneconomical level. However with other materials such as nylon and Lycra,the cap may he reusable. In the case of reusable caps, the cap materialpossessing the directional elasticity should be one wherein the materialreturns substantially to its original form.

The cap is preferably made of a single sheet of suitable material abovedefined, which forms a sleeve or belt. The term sleeve is used herein todefine a tube having free top and bottom margins but no free lateralmargins. and therefore, includes sheet material sewn together along itslateral side edges, or a plurality of panels of material securedtogether to form a tube. In the case where a plurality of panels aresecured together, (to form a sleeve), the unidirectional elasticity maybe incorporated into one of the panels rather than all four whereby thecap of this invention will still be capable of fitting substantially allhead sizes. In this selection however, the degree of elasticity shouldbe correspondingly larger than if all four panels had elasticity. Also,in other cases, material such as the nonwoven fabrics e.g. Keybak may bemanufactured so that the elasticity feature may be arranged about thefabric in predetermined areas whereby there are areas of nonelasticityand areas of unidirectional elasticity.

The sleeve length and diameter (width of the sleeve) may varyconsiderably. Typical dimensions for a cap are such that it will have alength of about 10 inches and a circumference. at the bottom margin inan unstretched condition, of approximately 22 inches. In most cases, itis preferred to make the length of the cap actually longer than thatrequired, whereby the bottom margin of the cap, when placed on the headcan be folded up about its lower edges to form a sweat band.

The cap of the present invention may also be adapted for use by turningthe above-described cap structure inside out as will be described ingreater detail hereinafter. The reversed cap structure results in a caphaving a continuous and smooth contour with a good close fitting dome ortop portion, and with a top interior structure formed by the joined topmargins of the first and second panels overlayed in part by opposedtriangular gussets, the apexes of the triangular gussets facing eachother and meeting along the line joining the first and second panel;conversely, the exterior structure of the top portion of the cap iscomposed of the end panel sections of the first and second panels withoverlayed triangular gussets (of two-ply thickness) formed by the thirdand fourth infolded panels with the apexes of the triangular gussetsfacing each other.

The method by which the panels of the cap are secured together at thetop margins can be carried out by any suitable means such as bystitching, stapling, suitable adhesives or heat sealing, depending onthe type of material being employed.

Having thus generally described the invention, reference will now bemade to the accompanying drawing, illustrating a preferred embodimentand in which:

FIG. I is a perspective view of an article according to this invention,showing the folds of a cap in a partially assembled condition;

FIG. 2 is a perspective view showing the cap in an assem bled condition;

FIG. 3 is vertical section showing, in pan, the process of reversing thehat;

FIG. 4 is a perspective view of the hat in a completely reversedcondition;

FIG. 5 is a bottom view of the hat of FIG. 4; and

FIG. 6 is a view showing the hat being worn with the bottom marginaledge up-turned to form a sweat band.

Referring now to the drawing there is illustrated a cap of the presentinvention. The cap consists of an endless belt or sleeve of nonwovenfabric material having a length of about 10 inches and a uniformcircumference of about 22 inches. To form the sleeve, the free sideedges of the sheet were stitched as shown by reference number 14. Thenonwoven fabric material used is that in Canadian Pat. 700,364, whichhas unidirectional elasticity. This unidirectional elasticity has beenincorporated into the cap structure in the width direction whereby thecap may be expanded to fit various head sizes. The particular materialused in this example is known in the trade as Keybak and had a grainweight of approximately 950 grains per square yard.

The hat includes Spair of first and second opposed substantiallyidentical panels 10 and 12 with third and fourth infolded panels and 22therebetween. The infolded panels are divided into panel sections 20a,20b, 22a and 2211 by crease lines 21 and 23 respectively. Panels 10, 12,20 and 22 all have approximately the same width of about 5 Xa'nches.

In the preferred embodiment as shown in the drawing, the panels 20 and22 and panels 10 and 12 are all joined together along their top marginaledges, (FIG. 2) by stitching 24, whereby the top of the cap iscompletely closed.

As will be seen in FIG. 2, triangular pockets are formed at the top ofthe cap, as indicated by reference numeral 26. which are defined by thejoint between the first and second panels and the infolded panels 20 and22A.

In use, the cap structure of the present invention is adapted to bereversed or turned inside out to form a contoured close fitting topsection. The reversing operation may be carried out by clasping theinterior top margins of the cap of FIG. 2 in the manner shown in FIG. 3and pulling the top margin'between the four panel sections, to result inthe structure shown in FIG. 4. As will be seen, the dome on the top ofthe cap, in reversed condition, is composed of the top sections of thefirst and second panels 10a and 12a meeting together-which panelsections extend substantially across the entire width of the dome. Panelsections 10a and l2a are overlayed in part by triangular gussets 28 and30, formed by panels 20 and 22 meeting along the lines of stitching,with the apexes of the triangular gussets facing each other. Triangulargussets 28 and 30 are actually two-ply in thickness by virtue of thepanel sections 20 and 22 being folded upon each other in the triangulararrangement.

The interior of the cap structure of FIG. 4 is shown in FIG. 5 andagain, panel sections, and it will be seen that the bottom portions ofpanels 10 and 12 form substantially completely the top interior portionwith underlying triangular gussets 28 and 30 which are those describedwith regard to FIG. 4.

In FIG. 6, there is illustrated a cap according to this invention beingwom. As will be seen, the structure ofthe cap of the present inventionpermits a substantially completely con toured dome portion. In thiscase, the lower edges of all four panels have been up-turned to form asweat band 32 along the lower portion of the cap.

The cap shown in the drawings may be constructed according toconventional techniques, for example by dividing a sleeve or tube of thematerial into four panels with two of the opposed panels being infoldedbetween the other pair of opposed panels. The degree to which theinfolded panels extend inwardly may vary. Dividing the sleeve into panelsections may be accomplished by, for example, pressing the fabric toform the panel section. or by any other suitable means, while infoldingone pair of panels between the other pair may be carried out by agusseting operation.

Once the sleeve has been divided into panels, the cap may then be sewnin across one free end in a single continuous line, by, for example,stitching as shown in the drawings, or by other suitable mean aspreviously mentioned.

It will be understood that various modifications can be made to the capof this invention without departing from the spirit and scope of theinvention. Thus, although the cap structure has been described withreference to panels, it will be understood that the panels do not haveto be panels as such since the body portion of the cap, whichencompasses the head, assumes a circular shape and therefore only thetop part of the cap may incorporate a definite panel shape.

We claim:

1. A cap having a tubular length of fabric folded to form a pair ofopposed first and second panels with top and bottom margins, third andfourth opposed panels inwardly folded between said first and secondpanels, said inwardly folded panels being folded into substantiallyequal panel sections, said third and fourth panels having top and bottommargins and being secured to at least one of said first or second panelsat the top margins thereof, said first and second panels being securedtogether at their top margins, and the panels are made ofa nonwovenfabric, said fabric having at least unidirectional elasticity and havinga fabric weight in the range of about ISO to 1,500 grains per squareyard, the nonwoven fabric being arranged so that the elasticity is atleast in the circumferential direction of the cap.

2. A method of forming a cap comprising the steps of forming a fabrichaving elasticity in at least one direction into a tubular length havinga top margin and a bottom margin, folding the fabric into four panels ofapproximately equal width, formfolded panels to the remaining panels atthe top margin olsnid panels and inverting the cap by pulling thesecured top margin through the lower margin to reverse the outer andinner surfaces of the cap, and folding the lower margin upwardly to inginwardly directed folds at approximately the center of 5formasweatbandeach of two opposed panels, securing the inwardly directed

1. A cap having a tubular length of fabric folded to form a pair ofopposed first and second panels with top and bottom margins, third andfourth opposed panels inwardly folded between said first and secondpanels, said inwardly folded panels being folded into substantiallyequal panel sections, said third and fourth panels having top and bottommargins and being secured to at least one of said first or second panelsat the top margins thereof, said first and second panels being securedtogether at their top margins, and the panels are made of a nonwovenfabric, said fabric having at least unidirectional elasticity and havinga fabric weight in the range of about 150 to 1,500 grains per squareyard, the nonwoven fabric being arranged so that the elasticity is atleast in the circumferential direction of the cap.
 2. A method offorming a cap comprising the steps of forming a fabric having elasticityin at least one direction into a tubular length having a top margin anda bottom margin, folding the fabric into four panels of approximatelyequal width, forming inwardly directed folds at approximately the centerof each of two opposed panels, securing the inwardly directed foldedpanels to the remaining panels at the top margin of said panels andinverting the cap by pulling the secured top margin through the lowermargin to reverse the outer and inner surfaces of the cap, and foldingthe lower margin upwardly to form a sweat band.